EPRI Low CO2 Emission Coal R&D For Kpic
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EPRI's research focuses on reducing CO2 emissions from coal power plants by enhancing thermal efficiency and advancing CO2 capture technologies, including pre-combustion, post-combustion, and oxy-combustion methods. The document highlights ongoing projects, including the development of advanced ultrasupercritical steam technology and various CO2 capture demonstrations, aiming to improve the economics and standards of IGCC plants. Collaboration with industry partners is emphasized to address the technological challenges and enhance the effectiveness of CO2 capture systems.
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EPRI Low CO2 Emission Coal R&D For Kpic
- 1. EPRI’s Low CO2 Emission Coal Power Research, Development and Demonstration Programs November 2009 Jeffrey N. Phillips Sr. Program Manager Advanced Generation Options © 2009 Electric Power Research Institute, Inc. All rights reserved. 1
- 2. Introduction • EPRI’s efforts are focused on: – Reducing CO2 emissions on kg/MWhr basis by increasing thermal efficiency of coal power plants – Improving the economics of pre-combustion, post- combustion, and oxy-combustion CO2 capture technologies • EPRI’s efforts range from lab tests to large demonstrations © 2009 Electric Power Research Institute, Inc. All rights reserved. 2
- 3. Decreasing CO2 Emissions with More Efficient Designs © 2009 Electric Power Research Institute, Inc. All rights reserved. 3
- 4. Increased Efficiency = Reduced Fuel & Emissions Advanced steam conditions can reduce CO2 emissions by 30-33% compared to average U.S. coal power plant Adapted by I.Wright, ORNL from B. Vitalis, Babcock Power © 2009 Electric Power Research Institute, Inc. All rights reserved. 4
- 5. Advanced-Ultrasupercritical Steam Boiler Consortium Phase I & II 1: Conceptual Design 2: Material Properties 3: Steamside Oxidation 4: Fireside Corrosion 8: Design Data & Rules (including Code 5: Welding interface) 6: Fabricability 7: Coatings Develop the materials technology to fabricate and operate a A-USC Steam Boiler with Steam Parameter up to 760°C 5 © 2009 Electric Power Research Institute, Inc. All rights reserved.
- 6. Advanced-Ultrasupercritical Steam Turbine Consortium Phase II • Steam Conditions from boiler and phase I turbine studies – 730°C, 39MPa Main Steam – 760°C, Re-heat – Size to 1000MW • Tasks – Rotor/Disc Testing (near full-size forgings) – Blade/Airfoil Alloy Testing – Valve Internals Alloy Testing – Rotor Alloy Welding and Characterization – Cast Casing Alloy Testing – Casing Welding and Repair © 2009 Electric Power Research Institute, Inc. All rights reserved. 6
- 7. Economic Analysis Shows Advanced USC Provides Cost-Effective CO2 Reductions 582ºC 680ºC SCPC A-USC Thermal Efficiency, %HHV 38.5 42.7 Levelized Cost of Electricity $/ 53.3 55.3 MWh CO2 emissions, kg/MWh 853 765 Avoided CO2 emissions cost, N/A 22.5 $/metric ton vs. 582ºC SCPC Reference: EPRI Technical Report 1015699, September 2008 © 2009 Electric Power Research Institute, Inc. All rights reserved. 7
- 8. CoalFleet IGCC User Design Basis Specification (see EPRI Report 1017501, Nov. 2009) • Defines power company technical requirements for a site- specific IGCC plant; supplier alliances to propose plants that meet the UDBS EPR I • UDBS represents major collaborative effort TION CIFICA IS SPE – All sectors of industry engaged US E R DESIG N BAS 101750 1 Report – 30+ people developed UDBS Ver. 9 – Approved by all CoalFleet members • Robust, 1600-page industry-developed and tested guideline, primer, and lessons-learned compendium • Flexible, yet promoting of standardized, optimized designs • Already in use by numerous CoalFleet participants © 2009 Electric Power Research Institute, Inc. All rights reserved. 8
- 9. IGCC Case Studies Performance Summary (see EPRI Report 1019368, October 2009) © 2009 Electric Power Research Institute, Inc. All rights reserved. 9
- 10. IGCC Engineering and Economic Evaluations 2009–10 Study Content • 50 Hz F-Frame Gas Turbine Cases – Northeast Netherlands site • Coal Type – Eastern Australian export coal • Gasification Technologies – General Electric, Siemens, Shell, Prenflo PDQ, Mitsubishi Heavy Industries, ConocoPhillips • Greenfield Carbon Capture and Storage • Sensitivity Analyses – G-Frame GT, Cost Estimates for CO2 Liquefaction and HP Gasification cases • 2008–09 Capital Costs Revisited © 2009 Electric Power Research Institute, Inc. All rights reserved. 10
- 11. ITM for Low Cost Oxygen Production Overview • A ceramic membrane to separate oxygen from air • Intermediate-sized 150 tons O2/day test unit integrated with 5-15 MWe turbomachinery system – Utilizes commercial-scale ceramic membrane modules for oxygen separation – Representative of arrangement for full-scale IGCC plant with CCS 0.5 tons O2/day ITM • Three-year program to design, build, and test system Modules – Team: Air Products (with Ceramatec and Siemens), DOE, and EPRI • EPRI has launched the collaborative – Builds on major investments by Air Products and DOE – Will incorporate real-world utility plant design and integration considerations – Forms a bridge to commercial IGCC application Images courtesy Air Products. – May enhance oxy-combustion applications © Air Products. All rights reserved. • Additional organizations are welcome to join the collaborative © 2009 Electric Power Research Institute, Inc. All rights reserved. 11
- 12. ITM for Low Cost Oxygen Production Potential Benefits • Reduces barriers to IGCC technology deployment – Decreases capital cost by ~7% – Decreases auxiliary power consumption by ~6% – Improves plant efficiency by ~1 percentage point – Reduces oxygen plant footprint by 50% – Reduces cooling water requirement by 60% • Large forecast growth in oxygen plant market should drive learning-by-doing cost reduction after commercialization • Potential use with oxy-combustion boilers © 2009 Electric Power Research Institute, Inc. All rights reserved. 12
- 13. Improving the Economics of CO2 Capture & Storage © 2009 Electric Power Research Institute, Inc. All rights reserved. 13
- 14. Challenges for Post-Combustion CO2 Capture • What to do with CO2? – SO2: ~ 1,400 ppmv in flue gas Can’t use consumable sorbents for CO2 capture (like those used for SO2 Capture). – CO2: ~140,000 ppmv in flue gas • Concentrating flue gas CO2 – Best option at present: scrub the gas with highly alkaline solutions which can then be stripped of the CO2 • Putting the CO2 in the ground (required pressures: 100 – 175 bar) • The overall capacity/efficiency penalty with current technology: – 750 MW plant will net 492 MW with CO2 Capture (258 MW loss) © 2009 Electric Power Research Institute, Inc. All rights reserved. 14
- 15. Capture Technologies Reviewed (see EPRI Report 1016995) Absorption, Liquid Absorption, Liquid, cont. Membrane, Active • MHI, KS-1 •InnoSepra • MTR • Chilled Ammonia (CAP) •CarbonTrap • RITE, Cardo polyimide • CANSOLV •TNO CASTOR2 • Tetramer Technologies • "7/2" MEA & PZ •JustCatch • Poly(Ionic Liquid) Membrane • CASTOR Solvent •CO2 Solution • NanoGloWa • IFP, Dual Phase •Three H Technologies, Inc. Membrane, Support • Econamine FG+ •Catalyte • Carbozyme • PowerSpan ECO2 Absorption, Solid • Coral • Ionic Liquids, Notre Dame •RTI • Kvaerner Membrane Contactor • Sargas •Hyperbranched Polyamine • PureStream • Skyonic Skymine •Polyethyleneimine (PEI) Cryogenic • AWL •Amine on inert support • CO2 Frosting • WowClean •CO2 Wheel, Toshiba • Enecogen • Ionic Liquids, U. S. Carolina Adsorption Biological Fixation • MEA:MDEA •Metal Organic Frameworks (MOFs) • • COCS Solvent, RITE UNLV PRB •Advanced Mesoporous Materials • • GRT Independence BioProducts •Heavy Reflux PSA • • Immobilized Activator Carbon Capture Corp. •CO2CRC Adsorbent • • Enzyme Catalysis GreenFuel •U. Akron • • AEEA GSCleanTech •U. Wyoming carbonaceous sorbent • • D3 Conc. Solar Photoreactor •ADA-ES • • HTC Purenergy Many new Algae Systems •VMI • RCO2 © 2009 Electric Power Research Institute, Inc. All rights reserved. Mineralization 15
- 16. Assessing Technical Readiness Level (TRL) TRL-9 Full-Scale Commercial • Most candidate CO2 removal Deployment technologies assessed are still a “twinkle in the eye” TRL-8 Sub-Scale Commercial Demonstration Plant • Significant development time required to bring even the TRL-7 Pilot Plant, 5 to 25% of full-scale most ready technology to TRL-6 Process Development Unit <5% TRL-9 TRL-5 Component Test in Relevant # Technologies at indicated TRL Environment TRL-4 Laboratory Component Testing TRL-3 Analytical, “Proof of Concept” TRL-2 Application Formulated TRL-1 Basic Principles Observed © 2009 Electric Power Research Institute, Inc. All rights reserved. 16
- 17. AEP-Alstom Chilled Ammonia Post-Combustion CO2 Capture Scale-Up – Overview • ~20 MWe demonstration facility at AEP’s Mountaineer plant • ~90,000 tonnes-CO2/yr – Next development step after 1.7 MWe R&D pilot at We Energies’ Pleasant Prairie Power Plant – Injection into two on-site wells PVF 2-23-09, Photo courtesy of AEP/Alstom. All rights reserved. – 1–5 year injection program plus post-injection monitoring – Started capturing CO2 on September 1 and injecting on October 1 • Alstom designed and built the facility, and will serve as lead operator for the first year. AEP may operate the facility for an additional 1-4 years. • EPRI will measure and report unit performance, operability, and reliability over project duration; EPRI will also monitor CO2 storage performance © 2009 Electric Power Research Institute, Inc. All rights reserved. 17
- 18. Southern Co.-MHI KM-CDR Advanced Amine Post-Combustion CO2 Capture – Overview • ~25 MWe demonstration facility at Alabama Power’s Plant Barry (~ 140,000 tonnes-CO2/year) – Potentially lower regeneration energy than other amines; less corrosive; low O2 degradation – Injection program under U.S. DOE’s Southeast Regional Carbon Sequestration Partnership (SECARB) Project—ongoing – 4 years of CO2 injection plus 4 years of post-injection monitoring – Startup scheduled for 4th Quarter 2010 • Southern Co. is leading the project and will install and operate the plant; MHI is designing the CO2 capture facility • EPRI will measure and report CO2 capture performance, operability, and reliability • EPRI is managing CO2 injection and monitoring operations under U.S. DOE research partnership © 2009 Electric Power Research Institute, Inc. All rights reserved. 18
- 19. Questions? Together…Shaping the Future of Electricity Jeffrey Phillips [email protected] Jong Kim [email protected] © 2009 Electric Power Research Institute, Inc. All rights reserved. 19